Unit construction system with interlocking u-shaped elements



p 1969 w. RATHKE ET AL 3,464,179

UNIT CONSTRUCTION SYSTEM WITH INTERLOCKING U-'SHAPED ELEMENTS Filed Aug. 18, 1967 6 Sheets-Sheet 1 FIG. 70

FIG. 7b

F /G. Id

FIG. 79

FIG. If I INVENTORS Wolfgang RATHKE Lyubomir SZABO Gert v.d. MUHLEN y Inez. earn their ATTORNEY Sept. 2, 1969 W. RATHKE ET AL UNIT CONSTRUCTION SYSTEM WITH INTERLOCKING U-SHAPED ELEMENTS Filed Aug. 18, 1967 FIG. 2a

6 Sheets-Sheet 2 INVENTORS Wolfgang RATHKE Lyubomir SZ ABO Gerr v. d. MUHLEN y fmez. ,QArH

their ATTORNEY p 2, 1969 w. RATHKE ET AL 3,464,179

UNIT CONSTRUCTION SYSTEM WITH INTERLOCKING U-SHAPED ELEMENTS Filed Aug. 18, 1967 6 Sheets-Sheet 5 FIG. 40 FIG. 4b

INVENTORS Wolfgang RATHKE Lyubomir SZABO Gert v. d. MUHLEN I KA e4. 24 T their ATTORNEY p 2, 1969 w. RATHKE ET AL 3,464,179

UNIT CONSTRUCTION SYSTEM WITH INTERLOCKING U-SHAPED ELEMENTS Filed Aug. 18, 1967 6 Sheets-Sheet -1 FIG. 6a

FIG. 6c FIG. 6d

INVENTORS Wolfgang RATHKE Lyubomlr SZABO Gert v. d. MUHLEN their ATTORNEY Sept. 2, 1969 w. RATHKE ET AL 3,

UNIT CONSTRUCTION SYSTEM WITH INTERLOCKING USHAPED ELEMENTS Filed Aug. 18, 1967 6 Sheets-Sheet 5 FIG.8

y INVENTORS Wolfgang RATH KE Lyubomir SZ ABO Gert v. cl. MUHLEN By mien, 1247/ their ATTORNEY p 1969 w. RATHKE ET Al. 3, 6 79 UNIT CONSTRUCTION SYSTEM WITH INTERLOCKING U-SHAPED ELEMENTS Filed Aug. 18, 1967 6 Sheets-Sheet 6 FIG. 77

INVENTORS Wolfgang RATHKE Lyubomir SZABO Gert v. d.'MUHLEN y "A24. RAT/4 their ATTORNEY United States Patent 3,464,179 UNIT CONSTRUCTION SYSTEM WITH INTER- LOCKING U-SHAPED ELEMENTS Wolfgang Rathke, Wuppertal-Elberfeld, Lyubomir Szabo,

Dusseldorf, and Gert V. D. Miihlen, Wuppertal-Elberfeld, Germany, assignors to Bau-Stahigewebe G.m.b.H., Dusseldorf-Oberkassel, Germany, a corporation of Germany Filed Aug. 18, 1967, Ser. No. 661,639 Claims priority, application Germany, Aug. 19, 1966, B 88,554 Int. Cl. E04c 1/10, 1/30; E04!) 5/08 US. Cl. 52584 7 Claims ABSTRACT OF THE DISCLOSURE In a unit construction system utilizing U-shaped unitary construction elements, the latter consist of. a rectangular base and a pair of side walls having a thickness equal to the wall thickness of said base and extending at right angles from the short ends of the rectangle. The height, width and length dimensions of the elements are whole number multiples of said wall thickness and are mutually interrelated in a predetermined manner, whereby to enable variant groups of elements to be assembled.

in varying spacial combinations and to be firmly mutually interlocked, substantially without the use of separate fastening devices or joining materials, in such a manner as to enable a progressive assemblage of any number of elements to form a uni-directional, two-directional or three-directional assembly structure, or combination, of desired configuration and mechanical stability.

. The present invention relates to the production of unidimensional, two-dimensional and three-dimensional con struction units, or combinations, by means of unitary construction elements designed and assembled according to the unit construction principle or method.

An object of the invention is the production of construction units of this type of any desired size and con,

figuration by the utilization of equal-sized prefabricated unitary construction elements of standard design and dimensions.

A more specific object of the invention is the provision of a unitary construction element of this type being designed for mutual interlocking of groups of three or more elements in varying forms or combinations by a simple clamping connection of the adjoining elements of a groupQor groups, in turn interconnected in similar fashion, substantially without the need of separate connecting intervening between the interlocked final assembly groups or elements. As a consequence, by the use of the system and assembly method according to the invention, the individual construction elements or groups may be pro-' gressively assembled to produce a final structure or assembly of any desired size and configuration, in the manner as will become further apparent as the description proceeds.

i The invention, both as to the foregoing and ancillary ice objects as well as novel aspects thereof, will be better understood from the following detailed description, taken in conjunction with the accompanying ,drawings forming part of this specification and wherein:

FIGS. la-lf are schematic isometric views of a series of unitary or standard construction elements embodying the principles of the invention, FIG. ld more clearly showing the specific design of the elements as based on the underlying concept of the invention;

FIGS. 2a2d illustrate in varying modifications a first mode of assemblage of a number of construction elements into a firmly clamped or interlocked group or structure according to the invention;

FIGS. 3a and 3b illustrate a variation of the assembly mode according to FIGS. 2a-2d;

FIGS. 4a-4d illustrate in varying modifications a further mode of assemblage of a group of construction elements in accordance with the invention;

FIGS. 50! and 5b represent variations of the basic assembly mode according to FIGS. 4a-4d;

FIGS. 6a-6d illustrate in varying modifications the third mode of assemblage of a group of construction elements according to the invention;

FIGS. 7a and 7b represent variations of the basic assembly mode according to FIGS. oat-6d;

FIG. 8 illustrates a modification of effecting frictional coupling connection or interlocking between adjoining construction elements or groups according to the invention;

FIG. 9 shows the position of a construction element according to the invention in a Cartesian reference system; and

FIGS. 10 and 11 show, by way of example, practical construction units obtainable by the use of unitary construction elements and assembly methods according to the invention.

With the foregoing objects in view, the invention involves generally the provision of a unitary U-shaped basic construction element of the referred to type having a free inner space or dimension which may be taken up in mutual frictional and force-locking engagement by a number of other and like elements arranged in mutually varyshaped clamping ing groups or arrangements, the clamping or mutual interlocking of the elements of a group or series of groups being efl'ected either by clamping of the elements themselves or the interposition of separate preferably wedgeelements engaging corresponding recesses in the side walls of the elements.

More particularly, in order to achieve the foregoing results and objects, the unitary construction element according to the present invention comprises essentially an oblong rectangular base and a pair of side walls having the same wall thickness as said base and extending at right angles from the short ends of the rectangle, to provide a U-shaped construction element or unit. According to the underlying design features of the invention, the

' length, width and height of the elements are whole number multiples of .said wall thickness, the height is equal tov the sum of the width plus said wall thickness, and the outer length of the elements is equal to the sum of twice said height and twice said wall thickness, that is, resulting in an inner free space or clear length equal to the sum of twice of the height of the elements. As a result of the foregoing design relationships, the elements may be combined in varying groups or sub-assemblies and mutually interlocked singly and in groups for the progressive assembly of any construction unit or structure of desired size and configuration, in the manner as will become further apparent as the description proceeds in reference to the drawings.

The mode of assembly or construction by means of unitary construction elements in accordance with the prescut invention has the advantage, among others, of overcoming the previous difliculties in using pre-fabricated construction elements, said difiiculties being due mainly to the requirement of a greater number of different parts or elements, whereas the elements forming the subject of the present invention are substantially alike in both the geometrical and structural or static sense. As a consequence, each of the elements may be individually incorporated at any point of the assembly structure in complying with prevailing static and geometric requirements or conditions.

Besides, the static design of the structures produced in accordance with the present invention is greatly simplified compared with conventional design systems or methods, in that the determination is limited to resistance of the elements of the composite structure subject to the most unfavorable load condition or stresses.

As will be understood, the new construction element and method of assembly according to the invention involves a decided deviation from the conventional construction methods, both as regards the mode of assembly and coupling of the unitary construction elements, as well as the geometry and appearance of the final struc ture or assemblies. While it is possible, by the use of the new construction elements and assembly methods, to build, for instance, garages, waiting rooms, or any other structures, the invention differs essentially from the conventional practice based on the dissolution of a predetermined final structure (building, etc.) into definite component units which are then re-assembled in the form of prefabricated parts into the final building or the like structures. In contrast, the new assembly method, according to the present invention, involves a completely new concept in building construction retaining as the only feature from the conventional methods the requirement of complying with predetermined tolerance variations of the units or elements, on the one hand, and the attainment of the requisite mechanical stability of the final construction units produced, on the other hand.

FIGS. la-lf illustrate the principle underlying the unit construction system according to the invention with FIG. 1d more clearly showing the design and relative dimensions of the unitary construction elements. Each of the U-shaped elements 1 of the series of FIGS. la-lf consists of an oblong rectangular base 2 of length L,,, width b and thickness d, and a pair of end walls 3 extending at right angles from the short sides of said base and having a thickness equal to the thickness d of said base. L, represents the interior or clear length of the elements, being equal to the exterior length L minus twice the wall thickness d.

According to the basic concept of the present invention, the width b and height h of the elements 1 of a series, such as shown by FIGS. la-lf, are predetermined whole number multiplies of the respective wall thickness d, that is, in the corresponding basic design formulas b=xd and h=yd, wherein x and y represent whole number proportionality factors or parameters, while the length L of the elements, according to a further feature of the invention, is determined by the relationship L =4 d+2b, as more clearly shown by FIG. 1d.

From the further and final design feature of the invention of b=hd, there results a relationship between the parameters x and y by substituting xd for b, according to the basic design formula, in the equation b=h--d, as follows:

By substituting y in the latter equation for h, derived from the basic design formula for h, the relation between x and y is obtained as follows:

From the latter, there may be in turn derived the equation for L expressed solely in terms of the parameter x, as follows:

Assuming, by way of example, .d==l,.the dimensions b, h and L for different whole number values of x vary according to the following table:

b=x=123456789 'h=23456789 10 From the foregoing it is seen'that the interior clear space or length L of the construction elements equals either the sum of two heights h, or the sum of two widths b plus two wall thicknesses d, or the sum of one height h plus one width b plus one wall thickness d, wherefore the possibility of three basic assembly modes according to the invention as illustrated by FIGS. 2a-2d, 3a and 3b; FIGS. 4a-4d, FIGS. 5a and 5b; and FIGS. 6a-6d, 7a and 7b, respectively, as described in further detail in the following.

In FIG. 2a, illustrating the first of the basic assembly modes according to the invention, the inner clear space of the construction element 4, having a dimension L is completely taken up by the sum of the wall thicknesses d of the elements 5 and 6 and the widths b of the elements 7 and 8. FIGS 2b-2d illustrate three further variations of the total of twelve possible mutually orthogonal positions of the basic assembly group or arrangement according to FIG. 2a. In other words, assembly of the elements is etfected by mutual pressfit or clamping engagement, or withoutany separate fastening or connect- 1ng means.

The same principle forms the basis of FIGS. 3a and 3b as utilized in theassembly mode according to FIGS. 2a-2d. Here again the interior space of the construction element 9 is completely taken up by the wall thicknesses d of the elements 10 and 11 and the widths b of the elements 12 and 13. FIG. 3b shows the construction group of FIG. 3a with the element 9 rotated by an angle of A second basic assembly mode according to the invention is shown by FIG. 4a, wherein the inner space between the lateral walls of the element 14 is taken up by the heights h of two elements 15 and 16 arranged with the free edges of their side walls abutting each other in the manner shown. FIGS. 4b4d again illustrate, in conjunction with FIG. 4a, four of the twelve possible spacial positions of this basic assembly group according to FIG. 4a. Besides, FIGS. 5a and 5b illustrate alternative arrangements utilizing the same assembly mode, that is, with the free innerspace of the element 17 being taken up by the two elements 18 and 19 arranged with their base plates abutting one another, to result in the elements being clamped into a T-shaped unit or structure.

The third of the possible assembly modes according to the invention is shown by FIG. 6a. Here again, the construction is predicated upon the clear or interior space of the element 20 being taken up by the sum of the wall thickness d of the element 21 plus the width b of the element 22 plus the height h of the element 23. FIGS. 6b-6d illustrate variations of the possible twelve assembly spacial combinations, while FIGS. 7a and 7b show an alternative construction group based on the same assembly mode. According to the latter, two construction elements 24 and 25 are assembled meander-fashion with the resultant intermediate space being taken up by the height h of element 26 and the width b of the element 27.

As will be seen from the foregoing, by the progressive use of any of the assembly modes described in the foregoing, construction units of any desired size and configuration, including single, two, and three-dimensional structures or combinations thereof, may be produced simply and expeditiously by means of the unitary basic construction element of the invention.

The three basic assembly modes or groups described in the foregoing may be varied, both within the groups per se and/or by combining two or more groups with each other, respectively. The progressive combination of an assembly and clamping or mutual interlocking of the elements or groups results in a beam, pillar, plate or wall-like final construction unit which may be embodied in any desired spacial enclosure or structure, as shown for example by FIGS. and 11. More particularly, FIG. 10 shows a supporting structure composed of elements according to the invention and mounted upon a pair of uprights, while FIG. 11 shows a construction unit embodying a plurality of closed spaces or cells.

In the foregoing, it has been assumed that the relative dimensions of the unitary construction elements are fabricated with sufiiciently close tolerance variations, to result in a frictional or pressfit engagement of the assembled elements or mutual interlocking of the various assembly structures into a compact body or unit. Advantageously, the clear or inner length L is designed to be slightly less than given in the foregoing, to ensure a close fit or clamping connection between the adjoining elements. Alternatively, a wedge-shaped recess may be provided in one or both side walls of the elements adapted to receive a separate locking element, to provide the required mechanical strength and stability of the structures, in the manner described in further detail hereafter.

In case where the material of the U-shaped construction elements, such as with the elements consisting of reinforced concrete, should result in too great a surface friction between the elements such as to prevent the attainment of a proper force-locking coupling engagement, the final geometrical form of a construction group, to ensure positive and effective coupling connections may be achieved subsequently to the assembly by the insertion between adjoining elements of special, preferably wedgeshaped, connecting or locking elements, in the manner more clearly shown in FIG. 8. In the latter, the inner face of the right-hand side wall 28 of the element 29 has an outwardly tapering shape, to provide a wedge-shaped space or recess for the insertion of a locking wedge 33 of any suitable material, to effect an efiicient force-locking connection between the element 29 and the elements 30 and 31, in the example shown.

The size of the construction elements and the material thereof may be varied within relatively wide limits, to suit any existing conditions and design requirements. Accordingly, the invention may encompass such widely separated fields or applications as educational construction sets made of plastic material and built on the unit construction principle, on the one hand, and concrete building constructions in which latter case the elements or construction elements may have the dimensions of a floor or room, such as a height of from 2.5-3 mm. and a length of from 4-5 m., respectively. The necessary wall thickness, or use of the particular type of element within a series, is determined by the laws of statics and in accordance with the design specifications of the existing work at hand. In the case of reinforced concrete as construction material, the elements are advantageously reinforced in a known manner in the vicinity of both the inner and outer surfaces thereof, preferably by means of conventional mesh reinforcing structures. In such a case, special consideration should be given to the reinforcement of the corners of the elements which may be called upon to assume substantial bending moments or stresses.

A further advantage of the unit construction element and mode of assembly according to the invention, utilizing geometrically equal construction elements of unitary type or size, is due to the fact that a single construction element may assume only twelve different and mutually orthogonal spacial positions within a Cartesian reference system. The location of the elements relative to each other in a construction group or assembly and to the zero or reference point of the system is determined by three spacial coordinates x 1 and Z respectively, as shown in FIG. 9. Adding thereto an order number, determining the sequence of the assembly or operations, of say three further digits will result in an eight-digit number (3 +2+3) positively determining the position of the elements within said space.

This enables a digital listing and processing on the basis of a model or prototype, in place of the usual complex layouts and specifications, thus in turn enabling programming and control of the assembly by means of a. digital computer. Besides, it appears possible, in using the present invention, to develop computer programs for testing the increasing loads or inner stresses as the assembly operations continue determined by reference to a simulated model or mock-up of the structures to be produced. Since the construction elements are basically alike in both a geometrical and static sense, the final data to be delivered by the computer will be limited to the control or monitoring of the admissibility of the next construction elements or units during an assembly operation. Accordingly, the new construction element and mode of assembly lends itself to a full automatic control by means of electronic computing devices.

In the foregoing the invention has been described in reference to a few illustrative devices or assembly modes. It will be evident, however, that variations and modifications, as well as the substitution of equivalent element and steps for those shown and described for illustration, may be made without departing from the broader scope and spirit of the invention. The specification and drawings are accordingly to be regarded in an illustrative rather than in a restrictive sense.

We claim:

1. A unitary construction element consisting of 1) an oblong rectangular base having a predetermined length, width and thickness,

(2) a pair of side walls extending at right angles form the short ends of said base,

(3) said side walls having a width and thickness equal to the width and thickness of said base,

(4) the height of said side walls, measured from the bottom surface of said base, being equal to the sum of said width and said thickness, and

(5) the inner distance between said side walls being equal to twice said height.

2. A construction element as claimed in claim 1, wherein said side walls have an inner surface slightly tapering from said base towards the outer ends thereof.

3. A unit construction system comprising (1) a plurality of unitary construction elements each consisting of (a) an oblong rectangular base having a predetermined length, width and thickness,

(b) a pair of side walls extending at right angles from the short ends of said base,

(c) said side walls having a width and thickness equal to the width and thickness of said base,

((1) the height of said side walls, measured from the bottom of said base, being equal to the sum of said width and said thickness, and

(e) the inner distance between said side walls being equal to twice said height, and

said elements being arranged (2) with combinations of the width, height and thick- 7 ness dimensions of a plurality of elements extending in the same direction and adjoining each other, to provide a total dimension of twice said height, and

(3) with a further element having its side Walls-embracing and locking together said first elements.

4. A unit construction system as claimed in claim 3, wherein said elements are arranged with the width dimensions of a first and second element and with the thickness dimensions of a third and fourth element adjoining said first and second elements.

5. In a unit construction system as claimed in claim 3, wherein said elements are arranged with the width dimensions of a first and second element and with the thickness dimensions of the bases of a third and fourth element adjoining said first and second elements.

6. In a unit construction system as claimed in claim 3, wherein said elements are arranged with the height dimension of a first element, the width dimension of a second element and the thickness dimension of a third element adjoining each other.

7. In a unit construction system as claimed in claim 3, wherein said elements are arranged with the height dimensions of a first and second element adjoining one another.

References Cited FOREIGN PATENTS 487,140 10/1952 Canada. 530,465 12/1940 Great Britain.

ALFRED C. PERHAM, Primary Examiner US. Cl. X.R. 

